EP1959460A2 - Method for manufacturing a transformer - Google Patents

Method for manufacturing a transformer Download PDF

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Publication number
EP1959460A2
EP1959460A2 EP08010496A EP08010496A EP1959460A2 EP 1959460 A2 EP1959460 A2 EP 1959460A2 EP 08010496 A EP08010496 A EP 08010496A EP 08010496 A EP08010496 A EP 08010496A EP 1959460 A2 EP1959460 A2 EP 1959460A2
Authority
EP
European Patent Office
Prior art keywords
winding
support
winding support
voltage
transformer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP08010496A
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German (de)
French (fr)
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EP1959460A3 (en
EP1959460B1 (en
Inventor
Volker Werner Hanser
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Individual
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Individual
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Filing date
Publication date
Priority claimed from DE102004048793A external-priority patent/DE102004048793B3/en
Application filed by Individual filed Critical Individual
Publication of EP1959460A2 publication Critical patent/EP1959460A2/en
Publication of EP1959460A3 publication Critical patent/EP1959460A3/en
Application granted granted Critical
Publication of EP1959460B1 publication Critical patent/EP1959460B1/en
Not-in-force legal-status Critical Current
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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F30/00—Fixed transformers not covered by group H01F19/00
    • H01F30/06—Fixed transformers not covered by group H01F19/00 characterised by the structure
    • H01F30/16—Toroidal transformers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F27/00—Details of transformers or inductances, in general
    • H01F27/24—Magnetic cores
    • H01F27/26—Fastening parts of the core together; Fastening or mounting the core on casing or support
    • H01F27/263—Fastening parts of the core together
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/061—Winding flat conductive wires or sheets
    • H01F41/063—Winding flat conductive wires or sheets with insulation
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/08—Winding conductors onto closed formers or cores, e.g. threading conductors through toroidal cores
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
    • H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
    • H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
    • H01F41/06—Coil winding
    • H01F41/09—Winding machines having two or more work holders or formers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
    • H01F30/00—Fixed transformers not covered by group H01F19/00
    • H01F30/06—Fixed transformers not covered by group H01F19/00 characterised by the structure
    • H01F30/12—Two-phase, three-phase or polyphase transformers
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/4902—Electromagnet, transformer or inductor
    • Y10T29/49071—Electromagnet, transformer or inductor by winding or coiling

Definitions

  • the invention relates to a high-voltage winding of a toroidal transformer, and their production method, for distribution transformers from a power of 100 kVA and a voltage from 6000 volts, based on toroidal technology.
  • the winding of the high voltage of toroidal distribution transformers high power and voltage for example, 2,000 kVA and 20,000 volts, is very complicated, time-consuming and thus expensive.
  • the high-voltage winding must be divided into several segments, so that the position voltage of the high-voltage winding can be reduced, and the reliability can be ensured. For example, at a voltage of 20,000 volts, 10 segments are provided. The voltage per segment is 2,000 volts. The layer tension is thereby reduced accordingly to a tenth. Furthermore, the voltage resistance to the low-voltage winding must be ensured.
  • a method of winding closed cores with wire in which a wire coil is parallel to a bobbin, a wire is drawn from the wire bobbin and guided by a guide wheel and wound up in layers on the bobbin.
  • a method for winding a closed ring core for high power transformers and chokes is known in which a winding device has a winding to be wound around the toroidal leg guide and a plurality along this guide through the toroidal core transportable, unrollable winding rollers.
  • At least one winding station with one on the winding support consisting of two voltage-resistant half-shells with side flange (at least one side flange with an insulated cavity for the implementation of the line material) of insulating high strength, which to a voltage-resistant round Unit assembled around the closed ring core, or the winding support by means of a casting mold around the toroidal core in a Druckgelierhabilit as a whole, for receiving the segments of the high voltage winding of the transformer, consisting of at least one electrical conductor and at least one insulating material with a winding carrier acting on the holding and Drehlagerung for rotatably supporting the winding support, is provided, which holding and pivot bearing a plurality of peripherally acting on the winding support rollers or the like rolling elements of which at least one, is connected to the drive and brake device to drive and decelerate the winding support so that the electrical conductor and the insulating material can be wound onto a closed ring core.
  • the winding support preferably consists of two high-strength half-shells with side flange, which are equipped with an overlapping latching device, or a hinge and an overlapping latching device, which are firmly assembled before the actual winding process to the closed ring core to a round unit, preferably with a special adhesive, so that the voltage resistance to the low-voltage winding can be guaranteed.
  • a further embodiment of the winding carrier provides that a divisible casting mold is placed around the closed ring core, with the aid of which the winding carrier, for example in a Druckgelierhabilit can be made directly on the closed ring core and is located after removal of the mold in one piece around the toroidal core and wound can.
  • the winding support has at least one side flange an insulated cavity with respect to the winding space, wherein at the lower end of the cavity an opening in the winding space of the winding support is to carry out the lower Wicklungsterrorisms, laterally past the winding, upwards.
  • This winding carrier has six advantageous functions firstly to ensure the basic voltage resistance to the undervoltage, secondly the holder for the high-voltage winding, third to allow the winding process, fourthly, the distance of the segments to each other by spacers allows fifth, a predetermined distance to the low-voltage winding is realized and sixth is the insulation of the lower Wicklungstearings by an isolated cavity opposite to the winding in the winding support in a small space upwards allows.
  • the winding carriers can be filled with the segments of the high-voltage winding with one or more insulating materials.
  • the coil carriers can be designed with a cover for insulation, leak-tightness or damage.
  • the winding support can be made electrically conductive to the outside, taking into account that no closed turn around the ring core itself arises. If necessary, this electrically conductive layer can be grounded or set to a defined potential.
  • a winding carrier For winding a winding carrier this is used in the holding and pivot bearing of the winding device and the winding material is supplied to the winding support of the (the) holding and pivot bearing spaced winding material storage roll (s) supplied.
  • the drive and braking device With the drive and braking device, at least one of the rolling elements is driven, or braked and rotated, whereby the winding support on which this rolling body circumferentially engages, gets into rotation.
  • Rolling elements not connected to the drive device serve as a holder for the winding carrier. To avoid frictional forces, these are preferably also rotatably mounted, so that a rolling or rolling of the winding carrier on these rolling elements is possible.
  • a frictional, optionally positive drive and braking device is provided between the winding support and at least the rolling element (s) connected to the drive and braking device.
  • a frictional connection can be realized in a structurally simple manner.
  • Winding material is removed from the winding material storage roll (s) and wound onto the winding carrier. Since the winding material storage roll (s) are fixed in place and are not moved around the winding support, large winding material storage rolls may be used, on which winding material for winding a plurality of winding supports may be sequentially applied. Windings can be wound for high-power toroidal distribution transformers, for example, over 10 MVA. As a winding material both round wires and flat strips can be used.
  • a particularly favorable embodiment provides that a plurality of circumferentially juxtaposed winding stations are provided for simultaneously winding a plurality of, in particular arranged on a ring core winding carrier.
  • a plurality of juxtaposed winding carriers can be wound in groups or all at the same time, as a result of which the time required for winding can be considerably reduced.
  • the number of winding stations can be chosen so that a winding station is available for each winding carrier.
  • This winding carriers can be wound in groups or all at the same time.
  • the control succeeds centrally.
  • the winding device is preferably divided into two levels, wherein the winding material storage roll (s) are arranged in the upper floor of the winding device. As a result, the usability is much easier.
  • the floors can also be reversed as needed.
  • At least one winding material storage roll with conductor material and at least one second winding material storage roll with insulation material for the simultaneous, layer-wise winding of Conductor material and insulation material are provided on the winding support. It is also possible to provide three, four, or five winding material storage rolls for simultaneously winding a winding carrier, wherein two, three, or four of the winding material storage rolls carry conductor material and a third, fourth, or fifth winding material storage roll carries insulating material for insulation. When using insulated conductive material, a winding material storage roll is sufficient.
  • the rolling elements are spring-loaded for adaptation to different winding carriers in the diameter and / or the outline shape and are preferably also supported in a damped manner.
  • This makes it possible to wind with a winding station winding support with circular cross-sections and different diameters, without making any structural changes to the winding station, or the holding and pivot bearing.
  • the rolling bearings can be positioned more or less spaced apart from the spring force according to the winding carrier diameter.
  • the dielectric strength can be realized and with the winding device, it is possible, the high-voltage windings for a toroidal distribution transformer in a relatively short time to wind.
  • a transformer in particular the high-voltage winding of a toroidal transformer high power, and their manufacturing process, wherein at least one winding station with a winding support, consisting of two voltage-resistant shells with side flange of high-strength insulating material, which to a voltage-resistant round unit to the closed Combined toroidal, for receiving the segments of the high-voltage winding of the transformer, consisting of an electrical conductor and an insulating material with a winding carrier engaging on the holding and pivot bearing for rotatably supporting the winding support, is provided, which holding and pivot bearing a plurality, peripherally acting on the winding support Rollers or the like rolling elements, of which at least one, is connected to the drive and braking device to drive the winding support and decelerate, so that the electrical conductor can be wound on a closed ring core with the insulating material.
  • a transformer in particular the high-voltage winding of a toroidal transformer high power, and their production method is provided, wherein the winding support is filled after or during the application of the high-voltage winding with solid, liquid or gaseous insulating material.
  • a transformer is provided, wherein at least one side flange of a winding carrier is provided with an insulated cavity, wherein at the lower end of the cavity an opening in the winding space of the winding support, for the implementation of the underlying winding start of the line material of the high-voltage winding upwards located.
  • a transformer wherein a divisible mold is placed around the closed ring core, with the aid of the winding support, for example, can be made in a Druckgelierbacter directly to the closed ring core and after removal of the mold is in one piece around the ring core and can be wound.
  • a transformer wherein the winding support consists of at least two parts with side flange, they are equipped with at least one overlapping latching device, or a hinge and an overlapping latching, the before the actual winding process to the closed ring core to a round unit , preferably with a special stress-resistant adhesive are joined together.
  • a transformer wherein the winding support consists of several insulating materials, and wherein the winding support has holders for the high-voltage winding, and wherein the side flanges of the winding carrier have a frictional or form-fitting surface, and wherein the winding support spacers for setting a has defined spacing of the segments to each other, and wherein the winding support has holders for setting a defined distance to the low-voltage winding.
  • a transformer wherein the coil carrier with a casting resin under atmospheric conditions, casting resin filling under vacuum, casting resin filling by a Druckgelierbacter or in a dense implementation with gaseous or liquid insulating materials, for example with nitrogen or an insulating oil, during or after the winding process is filled.
  • a transformer is provided, wherein the winding support can be carried out to be electrically conductive, taking into account that no closed turn around the toroid itself, this electrically conductive layer can be grounded, or can be set to a defined potential.
  • a transformer is provided, wherein for the simultaneous winding of several, in particular arranged on a toroidal winding a plurality of circumferentially juxtaposed winding stations are provided.
  • a transformer wherein the winding device is divided into two floors, wherein the winding material Vorratsungsrolle (s) in the upper floor of the winding device or vice versa are arranged.
  • a transformer wherein at least one winding material storage roll with conductor material and at least one second winding material storage roll with insulation material for the simultaneous, layer-wise winding of conductor material and insulation material are provided on the winding support, or three, four or five winding material storage rollers for simultaneously winding a winding carrier, wherein two, three or four, the winding material storage rolls of conductor material and a third, fourth or fifth winding material storage roll carries insulation material for insulation.
  • a transformer wherein the rolling elements are sprung for adaptation to the diameter and / or the outline of different winding support and are preferably also supported damped.
  • the invention also relates to the low-voltage winding of a toroidal distribution transformer, as well as their manufacturing process, a closed multi-stage transformer core high stability, electrically insulated to the outside, as well as on its manufacturing process, for distribution transformers in cast resin technology, from a power of 100 kVA and a voltage from 6000 V, based on the ring core technology.
  • Low-voltage windings for distribution transformers have very large cross-sections, for example, for 1,000 kVA this is about 1,500 mm2. Such cross sections are made for conventional distribution transformers in the leg construction with wide electrically conductive bands. In a toroidal distribution transformer, no such bands can be used due to the geometric conditions. The undervoltage winding would have to be produced in a very complex form by parallel connection of electrically insulated flat wires. Ring cores for toroidal transformers are today only produced for low power and low voltage in one-stage form. Multistage closed high strength toroidal transformer cores and insulated to the outside for distribution transformers and their manufacturing processes are not known.
  • the achievement of this object is that a turn of the low-voltage winding of an electrically conductive material is preformed in two halves, these two halves are electrically connected to each other around the closed ring core, wherein at least one half has a floor, so that a spiral winding, consisting is formed from several turns on the closed ring core, for the toroid, a thin magnetically conductive material is wound into a multi-stage closed toroidal transformer core, between the magnetically conductive material is an adhesive which mutually isolated the material (to avoid eddy currents) and the toroidal core solidified and the electrical insulation is obtained with respect to the low voltage winding with spacers or spacers made of electrically non-conductive material.
  • the toroidal transformer core can be completely cast with an electrically non-conductive casting resin high strength.
  • a further embodiment provides that the electrical insulation (core for undervoltage winding) is realized by at least three spacer rings or in each case three spacers per turn, which are fixedly mounted in the steps of the toroidal core. Subsequently, the toroidal core is coated with a varnish for insulation and protection against corrosion.
  • One turn of the undervoltage winding is preformed from two halves with electrically conductive material, for example aluminum with a cross-section of 1500 mm 2 . At least one half has a floor, so that from the individual halves a turn and from the turns a continuous spiral winding is formed, the shape of the floor sets the distance to the isolation of the turns against each other.
  • the individual halves can be screwed and / or welded.
  • the advantage of the toroidal core technology is that it allows toroidal distribution transformers to be realized in the highest power range, which are extremely low-loss and only about 50% of the operating costs of conventional distribution transformers in casting resin technology.
  • the toroidal distribution transformer refinances in a few years and, in addition, a significant amount of primary energy, for the conservation of resources and the environment, can be saved.
  • a transformer in particular a spiral undervoltage winding high cross-section and their manufacture, a multi-stage closed toroidal transformer high stability, from magnetically conductive and mutually insulated material, electrically insulated for undervoltage winding, and its manufacturing method, preferably a support frame with at least 3 Vorratsrollenvorlegien, each with a braking device, with at least 2 different widths of magnetically conductive material, at least three Klebersprühvorraumen, and at least three Aufwickelvortechniken with a drive system, at least three guide devices, a guide rail, and a cutting device is provided.
  • a transformer in particular a spiral undervoltage winding high cross-section and their manufacture, a multi-stage closed toroidal transformer high stability, from magnetically conductive and mutually insulated material, electrically insulated for undervoltage winding, and its manufacturing method, preferably a support frame with at least 3 Vorratsrollenvoridesen, each with a braking device, with at least 2 different widths of magnetically
  • each supply roll device as well as each take-up device is equipped with a drive and brake device.
  • a transformer is provided, wherein at least three spacer rings or three spacers per turn, are firmly attached in the gradations of the toroidal core.
  • a transformer is provided, the toroidal core being coated with a varnish for insulation and for protection against corrosion.
  • a transformer is provided wherein the toroidal transformer core is encased in a high strength cast resin.
  • the object is also achieved by a transformer, in particular a spiral low-voltage winding of high cross-section and their manufacture, a multi-stage closed toroidal transformer high stability, from magnetically conductive and mutually insulated material, electrically insulated for undervoltage winding, and its manufacturing process, wherein a turn of the low-voltage winding an electrically conductive material is preformed in two halves, these two halves are electrically conductively connected to each other around the closed ring core, wherein at least one half has a floor, so that a spiral winding, consisting of several turns on the closed ring core is formed.
  • a method wherein the winding halves are screwed together or / and welded.
  • FIG. 1 is a generally designated with 101 polyphase transformer having three stacked axially in the axial direction of ring cores 102.
  • adjacent ring cores 102 carry phase windings of different phases, wherein the phase windings are respectively applied to the ring cores 102 annularly enclosing bobbins 103.
  • bobbin 103 may be alternately arranged with primary and secondary windings next to each other or one above the other. It is also possible for primary and secondary windings to be applied together to a bobbin 103.
  • the ring cores 102 are arranged in a holding device 104 which has outer and inner guide rails 105a, 105b for forming a receiving region for the toroidal cores 102.
  • the guide rails 105a, 105b are each made of insulating material, so that the ring cores 102 and the phase windings on the bobbin 103 of the ring cores 102 are laterally outwardly insulated.
  • the holding device 104 has on its underside a bottom part 107, which likewise consists of insulating material.
  • insulating support elements 108 are provided for the lower ring core 102.
  • a plurality of spaced bearing elements 108 may be provided, or it is a continuous ring as a support element 108 is provided.
  • Spacers 109 are respectively provided between the individual ring cores 102 with which the ring cores 102 or the coil cores 103 respectively assigned to the toroidal cores 102 are fixed relative to one another in their position.
  • Insulating support elements 108 are again provided above the upper ring core 102, on which a cover part 110 rests and the toroidal cores 102 are also insulated on the upper side towards the outside.
  • the Indian FIG. 1 shown polyphase transformer 101 is formed as a three-phase transformer.
  • the connection points of the individual phase windings of the toroidal cores 102 or of the spool bodies 103, which are not illustrated in more detail, are each offset by 120 ° relative to one another.
  • the phase windings are thereby mechanically offset from one another by an angle which corresponds to the electrical phase shift or the electrical phase angle between the voltage signals of these phase windings.
  • the multi-phase transformer 101 can thereby be constructed compact and with reduced space requirements.
  • no or only little insulation measures are required, whereby costs are saved and the construction is simplified.
  • the ring cores 102 are formed with their respective bobbins 103 like a module.
  • the affected toroidal core can be exchanged for a replacement module or the defective module is electrically disconnected and a replacement module is provisionally connected to the polyphase transformer 101.
  • a replacement module is provisionally connected to the polyphase transformer 101.
  • FIG. 2 a winding device, generally designated 201, for winding winding carriers 202 is shown.
  • the winding device for winding winding carriers 202 with winding material 204a, 204b stored on rotatably mounted winding material storage rollers 203a has two winding stations 205, which are arranged at 90 degrees from one another, on a ring core 6 indicated as an option.
  • the winding stations 205 each have a support frame 207, with a holding and pivot bearing 208, for each one winding support 202.
  • the winding supports 202 are each arranged concentrically around the ring core 206, wherein an air gap 20 9 remains free between the ring core 206 and the winding supports 202.
  • the ring core 206 is held with a holding device, not shown, in the position shown.
  • the holding and pivot bearings 208 three each have on a roller holder 211, rotatably mounted rollers 210 as rolling elements, which act on the winding support 202.
  • Two of the rollers 210 support the winding support 202 while from below and thus form a stable support and the third roller 210 acts on the winding support 202, from above, so that the winding support 202 is practically pinched by three rollers 210 and accidentally releasing the winding support 202 of the Holding and pivot bearing 208 is avoided.
  • the rollers 210 are connected to a drive and brake device, not shown, with which the rollers are rotated in the direction of the arrows.
  • a frictional drive and braking device is provided between the rollers 210 and the winding support 202, so that when rotating the rollers 210 in a clockwise direction, the winding support 202 is rotated in opposite directions.
  • the winding material 204a, 204b is detached from the rotatably mounted winding material storage rollers 203a, 203b and wound onto the winding carrier 202.
  • the winding carriers 202 of the individual winding stations 205 can be wound simultaneously.
  • the winding carriers 202 are made of a high-strength insulating material, each coil-like with the winding space 213 and laterally defining flanges 214 are formed.
  • the insulation material is required for dielectric strength, in particular with respect to the low-voltage winding. The high strength is needed for the winding process, as well as the holding of the relatively heavy winding material.
  • the outer edges of these side flanges 214 serve as loading surfaces for the rollers 210.
  • the winding material 204a, 204b can be guided between the side flanges 214 on the winding support 202 without hindering the supply of the winding material 204a, 204b by the rollers 210.
  • the side flanges 214 form an insulation to adjacent coil carriers, as well as lateral boundary for the coil material 204a, 204b.
  • the rollers 210 are spring-loaded and damped at their roller holder 211, respectively. This allows the rollers 210, a holding and pivot bearing 208 move apart to use a winding support 202, in the holding and pivot bearing and remove again. In addition, it is possible to wind winding carriers of different sizes.
  • a first winding material storage roll 203a, with conductor material 4a, and a second winding material storage roll 203b with insulating material 204b, for simultaneously, layer by layer wrap the conductor and the insulating material, on a winding support 202 are provided.
  • the invention relates to a high-voltage winding of a toroidal transformer, as well as their method of manufacture, for distribution transformers, based on toroidal technology.
  • the winding station with one on the winding carrier consisting of two voltage-resistant half-shells with side flange High-strength insulating material, which is assembled to form a voltage-resistant round unit around the closed ring core, for receiving the segments of the high-voltage winding of the transformer, consisting of at least one electrical conductor and at least one insulating material with a holding and pivot bearing engaging on the winding support for rotatably supporting the winding support is, so that the electrical conductor and the insulating material can be wound onto a closed ring core.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Coils Or Transformers For Communication (AREA)
  • Manufacturing Cores, Coils, And Magnets (AREA)
  • Insulating Of Coils (AREA)

Abstract

The polyphase transformer (101) has several toroidal cores (102) adjacently arranged in an axial direction. The toroidal cores support phase windings of different phases. The connecting points of the phase windings of two adjacent toroidal cores are offset from one another in a peripheral direction. The offset of the geometric angles between the connecting points of the phase windings of two adjacent toroidal cores approximately corresponds to the phase shift to the electric phase angle between the voltage signals of these toroidal cores (102).

Description

Die Erfindung betrifft eine Oberspannungswicklung eines Ringkerntransformators, sowie deren Herstellungsverfahren, für Verteilungstransformatoren ab einer Leistung von 100 kVA und einer Spannung ab 6000 Volt, auf Basis der Ringkerntechnologie.The invention relates to a high-voltage winding of a toroidal transformer, and their production method, for distribution transformers from a power of 100 kVA and a voltage from 6000 volts, based on toroidal technology.

Das Bewickeln der Oberspannung von Ringkernverteilungstransformatoren hoher Leistung und Spannung, beispielsweise 2.000 kVA und 20.000 Volt, ist sehr aufwendig, zeitintensiv und somit teuer. Die Oberspannungswicklung muss in mehrere Segmente unterteilt werden, damit die Lagenspannung der Oberspannungswicklung reduziert, und die Betriebssicherheit gewährleistet werden kann. Bei einer Spannung von 20.000 Volt werden beispielsweise 10 Segmente vorgesehen. Dabei beträgt die Spannung pro Segment 2.000 Volt. Die Lagenspannung wird dadurch entsprechend auf ein Zehntel reduziert. Weiterhin ist die Spannungsfestigkeit gegenüber der Unterspannungswicklung sicher zu stellen.The winding of the high voltage of toroidal distribution transformers high power and voltage, for example, 2,000 kVA and 20,000 volts, is very complicated, time-consuming and thus expensive. The high-voltage winding must be divided into several segments, so that the position voltage of the high-voltage winding can be reduced, and the reliability can be ensured. For example, at a voltage of 20,000 volts, 10 segments are provided. The voltage per segment is 2,000 volts. The layer tension is thereby reduced accordingly to a tenth. Furthermore, the voltage resistance to the low-voltage winding must be ensured.

Man hat daher bereits Wickelvorrichtungen geschaffen, mit denen das Wickeln solcher Transformatorwicklungen vereinfacht wird. In der EP 0761 009 A1 ist beispielsweise eine Wickelvorrichtung beschrieben, bei der kleine Wickelrollen mit Wicklungsmaterial entlang einer einen Ringkern umgreifenden Führung durch den Ringkern hindurch bewegt werden und dabei Wi'cklungsmaterial auf den Ringkern abgewickelt wird. Diese Vorrichtung ist jedoch sehr aufwendig und die Spannungsfestigkeit ist nur eingeschränkt zu realisieren. Zudem ist es erforderlich, Wicklungsmaterial zunächst auf die kleinen, durch den Ringkern hindurchführbaren Wickelrollen aufzuspulen, was zusätzliche Zeit benötigt. Des weiteren ist es nur möglich, jeweils eine Wicklung gleichzeitig auf den Ringkern aufzubringen. Bei größeren Ringkernen mit einer Vielzahl von nebeneinander angeordneten Wicklungen (Segmente) wird daher zum Bewickeln aller Transformatorwicklungen viel Zeit benötigt.It has therefore already created winding devices with which the winding of such transformer windings is simplified. In the EP 0761 009 A1 For example, a winding device is described, in the small winding rollers with winding material along a ring core encompassing leadership through the toroidal core be moved while Wiicklungsmaterial is wound on the toroidal core. However, this device is very expensive and the dielectric strength is limited to realize. In addition, it is necessary to wind first winding material on the small, can be passed through the toroidal winding rollers, which requires additional time. Furthermore, it is only possible to apply one winding at a time to the toroidal core at the same time. For larger toroidal cores with a plurality of juxtaposed windings (segments), therefore, it takes a long time to wind all the transformer windings.

Aus der DE 44 26 138 C2 ist eine Gießform für eine Transformatorspule mit Kontrollmöglichkeit des Vergusses bekannt, wobei ein kragenartiges Teil des freien Endes eines beweglichen Mantelteils zusammen mit einem festen Randstück einen trichterartigen Einfüllschlitz in Längsrichtung der Spule bildet und der andere, feste Mantelteil als Halteelement für Anschlusselemente der Spule bei Vergussvorgang dient und der Einfüllschlitz am Umfang im bereich der Anschlusselemente positioniert ist, so dass dieser Bereich zumindest bei leicht geöffneten Mantelteil von außen durch den Einfüllschlitz einsehbar ist.From the DE 44 26 138 C2 is a mold for a transformer coil with control of the potting known, wherein a collar-like part of the free end of a movable shell part together with a fixed edge portion forms a funnel-like filling slot in the longitudinal direction of the coil and the other, solid shell portion serves as a holding element for connecting elements of the coil during potting and the filling slot is positioned on the circumference in the region of the connection elements, so that this region can be viewed from the outside through the filling slot, at least when the cover part is slightly open.

Aus der DE 1 916 637 A ist ein Verfahren zum Bewickeln von geschlossenen Kernen mit Draht bekannt, bei welchem eine Drahtspule parallel zu einem Spulenkörper liegt, von der Drahtspule ein Draht abgezogen und durch ein Führungsrad geführt und lagenförmig auf dem Spulenkörper aufgewickelt wird.From the DE 1 916 637 A A method of winding closed cores with wire is known, in which a wire coil is parallel to a bobbin, a wire is drawn from the wire bobbin and guided by a guide wheel and wound up in layers on the bobbin.

Aus der WO 95/12887 A1 ist ein Verfahren zum Bewickeln eines geschlossenen Ringkerns für Transformatoren und Drosseln hoher Leistungen bekannt, bei der eine Wickelvorrichtung eine den zu bewickelnden Ringkern-Schenkel umgreifende Führung sowie mehrere entlang dieser Führung durch den Ringkern hindurch transportierbare, abrollbare Wickelrollen aufweist.From the WO 95/12887 A1 a method for winding a closed ring core for high power transformers and chokes is known in which a winding device has a winding to be wound around the toroidal leg guide and a plurality along this guide through the toroidal core transportable, unrollable winding rollers.

Es besteht daher insbesondere die Aufgabe, eine Wickelvorrichtung und eine spannungsfeste Oberspannungswicklung der eingangs genannten Art zu schaffen, mit der das Bewickeln vereinfacht und beschleunigt erfolgen, sowie die notwendige Spannungsfestigkeit gegenüber der Unterspannungswicklung des Transformators realisiert werden kann.There is therefore in particular the task of creating a winding device and a high-voltage voltage winding of the type mentioned above, with which the winding can be simplified and accelerated, and the necessary dielectric strength against the low-voltage winding of the transformer can be realized.

Die erfindungsgemäße Lösung dieser Aufgabe besteht insbesondere darin, dass wenigstens eine Wickelstation mit einer am Wicklungsträger, bestehend aus zwei spannungsfesten Halbschalen mit Seitenflansch (mindestens ein Seitenflansch mit einem isolierten Hohlraum für die Durchführung des Leitungsmaterials), aus Isoliermaterial hoher Festigkeit, welche zu einer spannungsfesten runden Einheit um den geschlossenen Ringkern zusammengefügt, beziehungsweise der Wicklungsträger mittels einer Gießform um den Ringkern in einem Druckgelierverfahren im Ganzen gefertigt, zur Aufnahme der Segmente der Oberspannungswicklung des Transformators, bestehend aus mindestens einem elektrischen Leiter und mindestens einem Isolationsmaterial mit einer am Wicklungsträger angreifenden Halte- und Drehlagerung zum drehbaren Lagern des Wicklungsträgers, vorgesehen ist, welche Halteund Drehlagerung mehrere, umfangseitig an dem Wicklungsträger angreifende Rollen oder dergleichen Wälzkörper aufweist, von denen wenigstens eine, mit der Antriebs- und Bremsvorrichtung verbunden ist, um den Wicklungsträger anzutreiben und abzubremsen, damit der elektrische Leiter und das Isolationsmaterial auf einen geschlossenen Ringkern aufgewickelt werden kann.The achievement of this object is in particular that at least one winding station with one on the winding support, consisting of two voltage-resistant half-shells with side flange (at least one side flange with an insulated cavity for the implementation of the line material) of insulating high strength, which to a voltage-resistant round Unit assembled around the closed ring core, or the winding support by means of a casting mold around the toroidal core in a Druckgelierverfahren as a whole, for receiving the segments of the high voltage winding of the transformer, consisting of at least one electrical conductor and at least one insulating material with a winding carrier acting on the holding and Drehlagerung for rotatably supporting the winding support, is provided, which holding and pivot bearing a plurality of peripherally acting on the winding support rollers or the like rolling elements of which at least one, is connected to the drive and brake device to drive and decelerate the winding support so that the electrical conductor and the insulating material can be wound onto a closed ring core.

Damit wird es möglich, auf einen spannungsfesten Wicklungsträger aus Isoliermaterial zu wickeln, der einen geschlossenen Ringkern umgreift und um den Ringkern-Querschnitt gedreht wird. Durch den Einsatz des spannungsfesten Wicklungsträgers können die weiteren Isolationsmaßnahmen wesentlich reduziert werden. Weiterhin ist es nicht erforderlich, den Ringkern zunächst in zwei Hälften zu teilen um die Wicklungen aufschieben zu können. Die Herstellung eines Ringkernverteilungstransformators und die Nutzung der physikalischen Vorteile, insbesondere des wesentlich höheren Wirkungsgrads und die dadurch reduzierten Betriebskosten eines geschlossenen Ringkerns, wird dadurch wesentlich vereinfacht.This makes it possible to wind on a voltage-resistant winding carrier made of insulating material, which engages around a closed ring core and is rotated about the toroidal core cross-section. By using the voltage-resistant winding carrier, the other insulation measures can be significantly reduced. Furthermore, it is not necessary to first divide the ring core in half in order to postpone the windings can. The manufacture of a toroidal distribution transformer and the use of the physical advantages, in particular the much higher efficiency and the resulting reduced operating costs of a closed ring core, thereby significantly simplified.

Der Wicklungsträger besteht bevorzugt aus zwei hochfesten Halbschalen mit Seitenflansch, welche mit einer überlappenden Einrastvorrichtung, beziehungsweise einem Scharnier und einer überlappenden Einrastvorrichtung ausgestattet sind, die vor dem eigentlichen Wickelvorgang um den geschlossenen Ringkern zu einer runden Einheit, bevorzugt mit einem speziellen Klebstoff fest zusammengefügt werden, damit die Spannungsfestigkeit gegenüber der Unterspannungswicklung gewährleistet werden kann.The winding support preferably consists of two high-strength half-shells with side flange, which are equipped with an overlapping latching device, or a hinge and an overlapping latching device, which are firmly assembled before the actual winding process to the closed ring core to a round unit, preferably with a special adhesive, so that the voltage resistance to the low-voltage winding can be guaranteed.

Eine weitere Ausführungsform des Wicklungsträgers sieht vor, dass eine teilbare Gießform um den geschlossenen Ringkern gelegt, mit deren Hilfe der Wicklungsträger, beispielsweise in einem Druckgelierverfahren direkt am geschlossenen Ringkern gefertigt werden kann und sich nach dem Entfernen der Gießform einstückig um den Ringkern befindet und bewickelt werden kann. Der Wicklungsträger hat in mindestem einem Seitenflansch einen isolierten Hohlraum gegenüber dem Wickelraum, wobei sich am unteren Ende des Hohlraums eine Öffnung in den Wickelraum des Wicklungsträgers befindet, zur Durchführung des unteren Wicklungsanfangs, seitlich an der Wicklung vorbei, nach oben. Dieser Wicklungsträger hat sechs vorteilhafte Funktionen erstens die Grundspannungsfestigkeit gegenüber der Unterspannung zu gewährleisten, zweitens die Halterung für die Oberspannungswicklung, drittens den Wickelvorgang zu ermöglichen, viertens wird der Abstand der Segmente zueinander durch Distanzstücke ermöglicht, fünftens wird ein vorgegebener Abstand zur Unterspannungswicklung realisiert und sechstens wird die Isolation des unteren Wicklungsanfangs durch einen isolierten Hohlraum gegenüber der Wicklung in dem Wicklungsträger auf kleinstem Raum nach oben ermöglicht. Für die verschiedenen Einsatzgebiete von Ringkernverteilungstransformatoren und zur Sicherstellung der Spannungsfestigkeit können die Wicklungsträger mit den Segmenten der Oberspannungswicklung mit einem oder mehreren Isolationsmaterialen gefüllt werden. Zum Beispiel mit einem Gießharz unter atmosphärischen Bedingungen, Gießharzfüllung unter Vakuum, Gießharzfüllung durch ein Druckgelierverfahren oder bei einer dichten Ausführung mit gasförmigen oder flüssigen Isolationsstoffen, zum Beispiel mit Stickstoff oder einem geeigneten Öl. Bei Bedarf können die Wicklungsträger mit einer Abdeckung zur Isolation, zur Dichtigkeit oder gegen Beschädigung ausgeführt werden. Eine weitere Ausführungsform sieht vor, dass der Wicklungsträger nach außen hin elektrisch leitend ausgeführt werden kann, unter Berücksichtung dass keine geschlossene Windung um den Ringkern selbst entsteht. Diese elektrisch leitende Schicht kann bei Bedarf geerdet, beziehungsweise auf ein definiertes Potential gelegt werden.A further embodiment of the winding carrier provides that a divisible casting mold is placed around the closed ring core, with the aid of which the winding carrier, for example in a Druckgelierverfahren can be made directly on the closed ring core and is located after removal of the mold in one piece around the toroidal core and wound can. The winding support has at least one side flange an insulated cavity with respect to the winding space, wherein at the lower end of the cavity an opening in the winding space of the winding support is to carry out the lower Wicklungsanfangs, laterally past the winding, upwards. This winding carrier has six advantageous functions firstly to ensure the basic voltage resistance to the undervoltage, secondly the holder for the high-voltage winding, third to allow the winding process, fourthly, the distance of the segments to each other by spacers allows fifth, a predetermined distance to the low-voltage winding is realized and sixth is the insulation of the lower Wicklungsanfangs by an isolated cavity opposite to the winding in the winding support in a small space upwards allows. For the various fields of application of toroidal distribution transformers and for ensuring the Withstand voltage, the winding carriers can be filled with the segments of the high-voltage winding with one or more insulating materials. For example, with a casting resin under atmospheric conditions, casting resin filling under vacuum, casting resin filling by a Druckgelierverfahren or in a dense implementation with gaseous or liquid insulating materials, for example with nitrogen or a suitable oil. If necessary, the coil carriers can be designed with a cover for insulation, leak-tightness or damage. A further embodiment provides that the winding support can be made electrically conductive to the outside, taking into account that no closed turn around the ring core itself arises. If necessary, this electrically conductive layer can be grounded or set to a defined potential.

Zum Bewickeln eines Wicklungsträgers wird dieser in die Halte- und Drehlagerung der Wickelvorrichtung eingesetzt und das Wicklungsmaterial wird dem Wicklungsträger von der (den) Halte- und Drehlagerung beabstandet angeordneten Wicklungsmaterial-Bevorratungsrolle(n) zugeführt. Mit der Antriebsund Bremsvorrichtung wird zumindest einer der Wälzkörper angetrieben, beziehungsweise abgebremst und gedreht, wodurch der Wicklungsträger an dem dieser Wälzkörper umfangseitig angreift, in Rotation gerät. Nicht mit der Antriebsvorrichtung verbundene Wälzkörper dienen dabei als Halterung für den Wicklungsträger. Zur Vermeidung von Reibungskräften sind diese bevorzugt ebenfalls drehbar gelagert, so dass ein Abrollen beziehungsweise ein Abwälzen des Wicklungsträgers an diesen Wälzkörpern möglich ist.For winding a winding carrier this is used in the holding and pivot bearing of the winding device and the winding material is supplied to the winding support of the (the) holding and pivot bearing spaced winding material storage roll (s) supplied. With the drive and braking device, at least one of the rolling elements is driven, or braked and rotated, whereby the winding support on which this rolling body circumferentially engages, gets into rotation. Rolling elements not connected to the drive device serve as a holder for the winding carrier. To avoid frictional forces, these are preferably also rotatably mounted, so that a rolling or rolling of the winding carrier on these rolling elements is possible.

Es ist vorteilhaft, wenn zwischen dem Wicklungsträger und zumindest dem (den) mit der Antriebs- und Bremsvorrichtung verbundenen Wälzkörper(n) eine reibschlüssige, gegebenenfalls formschlüssige Antriebs- und Bremsvorrichtung vorgesehen ist. Eine reibschlüssige Verbindung ist auf konstruktiv einfache Weise realisierbar. Es ist jedoch auch möglich, eine formschlüssige Verbindung vorzusehen, beispielsweise durch eine Zahnung der Wälzkörper und der Seitenflansche der Wicklungsträger.It is advantageous if between the winding support and at least the rolling element (s) connected to the drive and braking device a frictional, optionally positive drive and braking device is provided. A frictional connection can be realized in a structurally simple manner. However, it is also possible to provide a positive connection, for example by a Teeth of the rolling elements and the side flanges of the winding carrier.

Durch die Rotation des Wicklungsträgers wird das Wicklungsmaterial von der (den) Wicklungsmaterial-Bevorratungsrolle(n) ab- und auf den Wicklungsträger aufgewickelt. Da die Wicklungsmaterial-Bevorratungsrolle(n) ortfest angeordnet sind und nicht um den Wicklungsträger herum bewegt werden, können große Wicklungsmaterial-Bevorratungsrollen verwendet werden, auf denen Wicklungsmaterial zum bewickeln mehrerer Wicklungsträger nacheinander aufgebracht sein kann. Es lassen sich Wicklungen für Ringkernverteilungstransformatoren hoher Leistung, beispielsweise ' über 10 MVA bewickeln. Als Wicklungsmaterial können sowohl Runddrähte als auch Flachbänder verwendet werden.As a result of the rotation of the winding carrier, the winding material is removed from the winding material storage roll (s) and wound onto the winding carrier. Since the winding material storage roll (s) are fixed in place and are not moved around the winding support, large winding material storage rolls may be used, on which winding material for winding a plurality of winding supports may be sequentially applied. Windings can be wound for high-power toroidal distribution transformers, for example, over 10 MVA. As a winding material both round wires and flat strips can be used.

Eine besonders günstige Ausführungsform sieht vor, dass zum gleichzeitigen Bewickeln mehrerer, insbesondere an einem Ringkern angeordneter Wicklungsträger mehrere, in Umfangsrichtung nebeneinander angeordnete Wickelstationen vorgesehen sind. Dadurch können mehrere nebeneinander angeordnete Wicklungsträger gruppenweise oder alle gleichzeitig bewickelt werden, wodurch die benötigte Zeit zum Bewickeln erheblich reduziert werden kann. Die Anzahl der Wickelstationen kann dabei so gewählt sein, dass für jeden Wicklungsträger eine Wickelstation vorhanden ist. Damit können Wicklungsträger in Gruppen oder alle gleichzeitig bewickelt werden. Die Steuerung erfolg dabei zentral. Bei dieser Ausführung wird die Wickelvorrichtung vorzugsweise in zwei Etagen unterteilt, wobei die Wicklungsmaterial-Bevorratungsrolle(n) in der oberen Etage der Wickelvorrichtung angeordnet werden. Dadurch wird die Bedienbarkeit wesentlich erleichtert. Die Etagen können je nach Bedarf auch umgekehrt werden.A particularly favorable embodiment provides that a plurality of circumferentially juxtaposed winding stations are provided for simultaneously winding a plurality of, in particular arranged on a ring core winding carrier. As a result, a plurality of juxtaposed winding carriers can be wound in groups or all at the same time, as a result of which the time required for winding can be considerably reduced. The number of winding stations can be chosen so that a winding station is available for each winding carrier. This winding carriers can be wound in groups or all at the same time. The control succeeds centrally. In this embodiment, the winding device is preferably divided into two levels, wherein the winding material storage roll (s) are arranged in the upper floor of the winding device. As a result, the usability is much easier. The floors can also be reversed as needed.

Es ist zweckmäßig, wenn wenigstens eine Wicklungsmaterial-Bevorratungsrolle mit Leitermaterial und wenigstens eine zweite Wicklungsmaterial-Bevorratungsrolle mit Isolationsmaterial zum gleichzeitigen, lagenweise Aufwickeln von Leitermaterial und Isolationsmaterial auf den Wicklungsträger vorgesehen sind. Es ist auch möglich, drei, vier oder fünf Wicklungsmaterial-Bevorratungsrollen zum gleichzeitigen Bewickeln eines Wicklungsträgers vorzusehen, wobei zwei, drei oder vier, der Wicklungsmaterial-Bevorratungsrollen Leitermaterial und eine dritte, vierte oder fünfte Wicklungsmaterial-Bevorratungsrolle Isolationsmaterial zum Isolieren trägt. Bei Verwendung von isoliertem Leitungsmaterial genügt eine Wicklungsmaterial-Bevorratungsrolle.It is expedient if at least one winding material storage roll with conductor material and at least one second winding material storage roll with insulation material for the simultaneous, layer-wise winding of Conductor material and insulation material are provided on the winding support. It is also possible to provide three, four, or five winding material storage rolls for simultaneously winding a winding carrier, wherein two, three, or four of the winding material storage rolls carry conductor material and a third, fourth, or fifth winding material storage roll carries insulating material for insulation. When using insulated conductive material, a winding material storage roll is sufficient.

Eine bevorzugte Ausführungsform sieht vor, dass die Wälzkörper zu Anpassung an im Durchmesser und/oder der Umrissform unterschiedliche Wicklungsträger gefedert und vorzugsweise auch gedämpft gelagert sind. Dadurch ist es möglich, mit einer Wickelstation Wicklungsträger mit kreisförmigen Querschnitten und unterschiedlichen Durchmessern zu bewickeln, ohne konstruktive Änderungen an der Wickelstation, beziehungsweise der Halte- und Drehlagerung vorzunehmen. Dazu können die Wälzlager gegen die Federkraft mehr oder weniger entsprechend dem Wicklungsträger-Durchmesser beabstandet positioniert werden. Darüber hinaus ist es möglich, auch Wicklungsträger mit einem unrunden, beispielsweise ovalen Querschnitt zu bewickeln. Durch die gefederte Lagerung liegen die Wälzkörper auch bei nichtrundem Querschnitt des Wicklungsträger stets an diesem an, wodurch einerseits die Halterung und andererseits der Rotationsantrieb des Wicklungsträgers sichergestellt sind.A preferred embodiment provides that the rolling elements are spring-loaded for adaptation to different winding carriers in the diameter and / or the outline shape and are preferably also supported in a damped manner. This makes it possible to wind with a winding station winding support with circular cross-sections and different diameters, without making any structural changes to the winding station, or the holding and pivot bearing. For this purpose, the rolling bearings can be positioned more or less spaced apart from the spring force according to the winding carrier diameter. In addition, it is possible to wrap also winding carrier with a non-round, for example oval cross-section. Due to the sprung bearing, the rolling elements are always in non-circular cross-section of the winding support to this, whereby on the one hand the holder and on the other hand, the rotational drive of the winding carrier are ensured.

Es ist zweckmäßig, wenn für die Wicklungsmaterial-Bevorratungsrolle(n) jeweils eine Drehlagerung mit einer Antriebsund Bremsvorrichtung vorgesehen wird, so dass ein definierter Wickelzug eingehalten werden kann.It is expedient if in each case a rotary bearing with a drive and brake device is provided for the winding material storage roll (s), so that a defined winding tension can be maintained.

Mit dem erfindungsgemäßen Wicklungsträger für die Oberspannungswicklung eines Ringkernverteilungstransformators kann die Spannungsfestigkeit realisiert werden und mit der Wickelvorrichtung ist es möglich, die Oberspannungswicklungen für einen Ringkernverteilungstransformator in vergleichsweise kurzer Zeit zu bewickeln.With the winding carrier according to the invention for the high voltage winding of a toroidal distribution transformer, the dielectric strength can be realized and with the winding device, it is possible, the high-voltage windings for a toroidal distribution transformer in a relatively short time to wind.

Die Aufgabe wird gelöst durch einen Transformator, insbesondere die Oberspannungswicklung eines Ringkerntransformators hoher Leistung, sowie deren Herstellungsverfahren, wobei wenigstens eine Wickelstation mit einer am Wicklungsträger, bestehend aus zwei spannungsfesten Halbschalen mit Seitenflansch aus Isoliermaterial hoher Festigkeit, welche zu einer spannungsfesten runden Einheit um den geschlossenen Ringkern zusammengefügt, zur Aufnahme der Segmente der Oberspannungswicklung des Transformators, bestehend aus einem elektrischen Leiter und einem Isolationsmaterial mit einer am Wicklungsträger angreifenden Halte- und Drehlagerung zum drehbaren Lagern des Wicklungsträgers, vorgesehen ist, welche Halte- und Drehlagerung mehrere, umfangseitig an dem Wicklungsträger angreifende Rollen oder dergleichen wälzkörper aufweist, von denen wenigstens eine, mit der Antriebsund Bremsvorrichtung verbunden ist, um den Wicklungsträger anzutreiben und abzubremsen, damit der elektrische Leiter mit dem Isolationsmaterial auf einen geschlossenen Ringkern aufgewickelt werden kann.The object is achieved by a transformer, in particular the high-voltage winding of a toroidal transformer high power, and their manufacturing process, wherein at least one winding station with a winding support, consisting of two voltage-resistant shells with side flange of high-strength insulating material, which to a voltage-resistant round unit to the closed Combined toroidal, for receiving the segments of the high-voltage winding of the transformer, consisting of an electrical conductor and an insulating material with a winding carrier engaging on the holding and pivot bearing for rotatably supporting the winding support, is provided, which holding and pivot bearing a plurality, peripherally acting on the winding support Rollers or the like rolling elements, of which at least one, is connected to the drive and braking device to drive the winding support and decelerate, so that the electrical conductor can be wound on a closed ring core with the insulating material.

In einem weiteren Ausführungsbeispiel ist ein Transformator, insbesondere die Oberspannungswicklung eines Ringkerntransformators hoher Leistung, sowie deren Herstellungsverfahren vorgesehen, wobei der Wicklungsträger nach oder während dem Aufbringen der Oberspannungswicklung mit festem, flüssigen oder gasförmigem Isolationsmaterial gefüllt wird.In a further embodiment, a transformer, in particular the high-voltage winding of a toroidal transformer high power, and their production method is provided, wherein the winding support is filled after or during the application of the high-voltage winding with solid, liquid or gaseous insulating material.

In einem weiteren Ausführungsbeispiel ist ein Transformator vorgesehen, wobei mindestens ein Seitenflansch eines Wicklungsträgers mit einem isolierten Hohlraum ausgestattet ist, wobei sich am unteren Ende des Hohlraums eine Öffnung in den Wickelraum des Wicklungsträgers, für die Durchführung des unten liegenden Wicklungsanfangs des Leitungsmaterials der Oberspannungswicklung nach oben befindet.In a further embodiment, a transformer is provided, wherein at least one side flange of a winding carrier is provided with an insulated cavity, wherein at the lower end of the cavity an opening in the winding space of the winding support, for the implementation of the underlying winding start of the line material of the high-voltage winding upwards located.

In einem weiteren Ausführungsbeispiel ist ein Transformator vorgesehen, wobei eine teilbare Gießform um den geschlossenen Ringkern gelegt ist, mit deren Hilfe der Wicklungsträger, beispielsweise in einem Druckgelierverfahren direkt am geschlossenen Ringkern gefertigt werden kann und sich nach dem Entfernen der Gießform einstückig um den Ringkern befindet und bewickelt werden kann.In a further embodiment, a transformer is provided, wherein a divisible mold is placed around the closed ring core, with the aid of the winding support, for example, can be made in a Druckgelierverfahren directly to the closed ring core and after removal of the mold is in one piece around the ring core and can be wound.

In einem weiteren Ausführungsbeispiel ist ein Transformator vorgesehen, wobei der Wicklungsträger aus mindestens zwei Teilen mit Seitenflansch besteht, diese mit mindestens einer überlappenden Einrastvorrichtung, beziehungsweise einem Scharnier und einer überlappenden Einrastvorrichtung ausgestattet sind, die vor dem eigentlichen Wickelvorgang um den geschlossenen Ringkern zu einer runden Einheit, bevorzugt mit einem speziellen spannungsfesten Klebstoff zusammengefügt werden.In a further embodiment, a transformer is provided, wherein the winding support consists of at least two parts with side flange, they are equipped with at least one overlapping latching device, or a hinge and an overlapping latching, the before the actual winding process to the closed ring core to a round unit , preferably with a special stress-resistant adhesive are joined together.

In einem weiteren Ausführungsbeispiel ist ein Transformator vorgesehen, wobei der Wicklungsträger aus mehren Isolationsmaterialien besteht, und wobei der Wicklungsträger Halterungen für die Oberspannungswicklung aufweist, und wobei die Seitenflansche des Wicklungsträgers eine reibschlüssige, beziehungsweise formschlüssige Oberfläche besitzen, und wobei der Wicklungsträger Distanzstücke zur Einstellung von einem definierter Abstand der Segmente zueinander aufweist, und wobei der Wicklungsträger Halterungen zur Einstellung eines definierten Abstand zur Unterspannungswicklung besitzt.In a further embodiment, a transformer is provided, wherein the winding support consists of several insulating materials, and wherein the winding support has holders for the high-voltage winding, and wherein the side flanges of the winding carrier have a frictional or form-fitting surface, and wherein the winding support spacers for setting a has defined spacing of the segments to each other, and wherein the winding support has holders for setting a defined distance to the low-voltage winding.

In einem weiteren Ausführungsbeispiel ist ein Transformator vorgesehen, wobei der Wicklungsträger mit einem Gießharz unter atmosphärischen Bedingungen, Gießharzfüllung unter Vakuum, Gießharzfüllung durch ein Druckgelierverfahren oder bei einer dichten Ausführung mit gasförmigen oder flüssigen Isolationsstoffen, zum Beispiel mit Stickstoff oder einem isolierenden Öl, während oder nach dem Wickelvorgang gefüllt wird.In a further embodiment, a transformer is provided, wherein the coil carrier with a casting resin under atmospheric conditions, casting resin filling under vacuum, casting resin filling by a Druckgelierverfahren or in a dense implementation with gaseous or liquid insulating materials, for example with nitrogen or an insulating oil, during or after the winding process is filled.

In einem weiteren Ausführungsbeispiel ist ein Transformator vorgesehen, wobei der Wicklungsträger nach außen hin elektrisch leitend ausgeführt werden kann, unter Berücksichtung dass keine geschlossene Windung um den Ringkern selbst entsteht, diese elektrisch leitende Schicht geerdet werden kann, beziehungsweise auf ein definiertes Potential gelegt werden kann.In a further embodiment, a transformer is provided, wherein the winding support can be carried out to be electrically conductive, taking into account that no closed turn around the toroid itself, this electrically conductive layer can be grounded, or can be set to a defined potential.

In einem weiteren Ausführungsbeispiel ist ein Transformator vorgesehen, wobei zum gleichzeitigen Bewickeln mehrerer, insbesondere an einem Ringkern angeordneter Wicklungsträger mehrere, in Umfangsrichtung nebeneinander angeordnete Wickelstationen vorgesehen sind.In a further embodiment, a transformer is provided, wherein for the simultaneous winding of several, in particular arranged on a toroidal winding a plurality of circumferentially juxtaposed winding stations are provided.

In einem weiteren Ausführungsbeispiel ist ein Transformator vorgesehen, wobei die Wickelvorrichtung in zwei Etagen unterteilt, wobei die Wicklungsmaterial-Bevorratungsrolle(n) in der oberen Etage der Wickelvorrichtung oder umgekehrt angeordnet werden.In another embodiment, a transformer is provided, wherein the winding device is divided into two floors, wherein the winding material Vorratsungsrolle (s) in the upper floor of the winding device or vice versa are arranged.

In einem weiteren Ausführungsbeispiel ist ein Transformator vorgesehen, wobei wenigstens eine Wicklungsmaterial-Bevorratungsrolle mit Leitermaterial und wenigstens eine zweite Wicklungsmaterial-Bevorratungsrolle mit Isolationsmaterial zum gleichzeitigen, lagenweise Aufwickeln von Leitermaterial und Isolationsmaterial auf den Wicklungsträger vorgesehen sind, beziehungsweise drei, vier oder fünf Wicklungsmaterial-Bevorratungsrollen zum gleichzeitigen Bewickeln eines Wicklungsträgers, wobei zwei, drei oder vier, der Wicklungsmaterial-Bevorratungsrollen Leitermaterial und eine dritte, vierte oder fünfte Wicklungsmaterial-Bevorratungsrolle Isolationsmaterial zum Isolieren trägt.In a further exemplary embodiment, a transformer is provided, wherein at least one winding material storage roll with conductor material and at least one second winding material storage roll with insulation material for the simultaneous, layer-wise winding of conductor material and insulation material are provided on the winding support, or three, four or five winding material storage rollers for simultaneously winding a winding carrier, wherein two, three or four, the winding material storage rolls of conductor material and a third, fourth or fifth winding material storage roll carries insulation material for insulation.

In einem weiteren Ausführungsbeispiel ist ein Transformator vorgesehen, wobei die Wälzkörper zu Anpassung an im Durchmesser und/oder der Umrissform unterschiedliche Wicklungsträger gefedert und vorzugsweise auch gedämpft gelagert sind.In a further embodiment, a transformer is provided, wherein the rolling elements are sprung for adaptation to the diameter and / or the outline of different winding support and are preferably also supported damped.

Die Erfindung bezieht sich außerdem auf die Unterspannungswicklung eines Ringkernverteilungstransformators, sowie auf deren Herstellungsverfahren, einen geschlossenen mehrstufigen Transformatorkern hoher Stabilität, nach außen hin elektrisch isoliert, sowie auf dessen Herstellungsverfahren, für Verteilungstransformatoren in Gießharztechnik, ab einer Leistung von 100 kVA und einer Spannung ab 6000 V, auf Basis der Ringkerntechnologie.The invention also relates to the low-voltage winding of a toroidal distribution transformer, as well as their manufacturing process, a closed multi-stage transformer core high stability, electrically insulated to the outside, as well as on its manufacturing process, for distribution transformers in cast resin technology, from a power of 100 kVA and a voltage from 6000 V, based on the ring core technology.

Unterspannungswicklungen für Verteilungstransformatoren haben sehr große Querschnitte, beispielsweise für 1.000 kVA sind dies ca. 1.500 mm2. Solche Querschnitte werden für konventionelle Verteilungstransformatoren in der Schenkelbauweise mit breiten elektrisch leitenden Bändern hergestellt. Bei einem Ringkernverteilungstransformator können infolge der geometrischen Verhältnisse keine solche Bänder verwendet werden. Die Unterspannungswicklung müsste in sehr aufwendiger Form durch Parallelschalten von elektrisch isolierten Flachdrähten hergestellt werden. Ringkerne für Ringkerntransformatoren werden heute nur für kleine Leistungen und Niederspannungen in einstufiger Form hergestellt. Mehrstufige geschlossene Ringkerntransformatorkerne hoher Festigkeit und nach außen isoliert, für Verteilungstransformatoren und deren Fertigungsverfahren, sind nicht bekannt.Low-voltage windings for distribution transformers have very large cross-sections, for example, for 1,000 kVA this is about 1,500 mm2. Such cross sections are made for conventional distribution transformers in the leg construction with wide electrically conductive bands. In a toroidal distribution transformer, no such bands can be used due to the geometric conditions. The undervoltage winding would have to be produced in a very complex form by parallel connection of electrically insulated flat wires. Ring cores for toroidal transformers are today only produced for low power and low voltage in one-stage form. Multistage closed high strength toroidal transformer cores and insulated to the outside for distribution transformers and their manufacturing processes are not known.

Es besteht das Problem, eine Unterspannungswicklung mit einem elektrischen Leiter hohen Querschnitts um einen geschlossenen Ringkern anzubringen, damit ein Ringkernverteilungstransformator hoher Leistung (ab 100 kVA bis in den Megawattbereich) zu realisieren ist. Es besteht die Aufgabe, eine Unterspannungswicklung mit einem elektrischen Leiter hohen Querschnitts um einen geschlossenen Ringkern anzubringen und einen geschlossenen mehrstufigen Ringkerntransformatorkern hoher Festigkeit, welcher nach außen hin elektrisch isoliert ist und ein dafür rationelles, maschinelles Herstellungsverfahren zu schaffen, damit die Produktion von Ringkernverteilungstransformatoren ermöglicht wird.There is the problem of mounting a low-voltage winding with a high-section electrical conductor around a closed ring core in order to realize a high-power toroidal distribution transformer (from 100 kVA up to the megawatt range). It is an object to provide a low-voltage winding with a high-section electrical conductor around a closed ring core and a closed multi-stage high-strength toroidal transformer core electrically insulated from the outside and providing a rational machine manufacturing process to enable the production of toroidal distribution transformers ,

Die erfindungsgemäße Lösung dieser Aufgabe besteht darin, dass eine Windung der Unterspannungswicklung aus einem elektrisch leitendem Material in zwei Hälften vorgeformt wird, diese zwei Hälften um den geschlossenen Ringkern elektrisch miteinander verbunden werden, wobei mindestens eine Hälfte eine Etage aufweist, damit eine spiralförmige Wicklung, bestehend aus mehreren Windungen auf dem geschlossenen Ringkern entsteht, für den Ringkern, ein dünnes magnetisch leitendes Material zu einem mehrstufigen geschlossenen Ringkerntransformatorkern gewickelt wird, sich zwischen dem magnetisch leitendem Material ein Klebstoff befindet, welcher das Material gegenseitig isoliert (zur Vermeidung von Wirbelströmen) und den Ringkern verfestigt und die elektrische Isolation gegenüber der Unterspannungswicklung mit Distanzringen oder Distanzstücken aus elektrisch nicht leitenden Material erlangt wird. Zur Steigerung der Festigkeit und zur elektrischen Isolation nach außen hin, kann der Ringkerntransformatorenkern mit einem elektrisch nicht leitenden Gießharz hoher Festigkeit komplett eingegossen werden.The achievement of this object is that a turn of the low-voltage winding of an electrically conductive material is preformed in two halves, these two halves are electrically connected to each other around the closed ring core, wherein at least one half has a floor, so that a spiral winding, consisting is formed from several turns on the closed ring core, for the toroid, a thin magnetically conductive material is wound into a multi-stage closed toroidal transformer core, between the magnetically conductive material is an adhesive which mutually isolated the material (to avoid eddy currents) and the toroidal core solidified and the electrical insulation is obtained with respect to the low voltage winding with spacers or spacers made of electrically non-conductive material. To increase the strength and electrical insulation to the outside, the toroidal transformer core can be completely cast with an electrically non-conductive casting resin high strength.

Eine weitere Ausführungsform sieht vor, dass die elektrische Isolation (Kern zur Unterspannungswicklung) durch mindestens drei Distanzringe oder jeweils drei Distanzstücke pro Windung, welche in den Stufungen des Ringkerns fest angebracht werden, realisiert wird. Anschließend wird der Ringkern mit einem Lack zur Isolation und zum Schutz gegen Korrosion überzogen.A further embodiment provides that the electrical insulation (core for undervoltage winding) is realized by at least three spacer rings or in each case three spacers per turn, which are fixedly mounted in the steps of the toroidal core. Subsequently, the toroidal core is coated with a varnish for insulation and protection against corrosion.

Eine Windung der Unterspannungswicklung wird aus zwei Hälften mit elektrisch leitendem Material vorgeformt, beispielsweise aus Aluminium mit einem Querschnitt von 1.500 mm2. Mindestens eine Hälfte weist eine Etage auf, damit aus den einzelnen Hälften eine Windung und aus den Windungen eine fortlaufende spiralförmige Wicklung entsteht, wobei die Form der Etage den Abstand zur Isolation der Windungen gegeneinander vorgibt. Die einzelnen Hälften können verschraubt und/oder verschweißt werden.One turn of the undervoltage winding is preformed from two halves with electrically conductive material, for example aluminum with a cross-section of 1500 mm 2 . At least one half has a floor, so that from the individual halves a turn and from the turns a continuous spiral winding is formed, the shape of the floor sets the distance to the isolation of the turns against each other. The individual halves can be screwed and / or welded.

Dadurch wird es ermöglicht, eine Unterspannungswicklung mit beliebig großem Querschnitt in relativ kurzer Zeit zu realisieren.This makes it possible to realize a low-voltage winding with arbitrarily large cross section in a relatively short time.

Der Vorteil der Ringkerntechnologie besteht darin, dass man damit Ringkernverteilungstransformatoren bis in den höchsten Leistungsbereich realisieren kann, welche extrem verlustarm sind und nur noch ca. 50% der Betriebkosten von konventionellen Verteilungstransformatoren in Gießharztechnik aufweisen. Dadurch refinanziert sich der Ringkernverteilungstransformator in wenigen Jahren und zusätzlich kann ein bedeutender Teil an Primärenergie, zur Schonung von Ressourcen und der Umwelt, eingespart werden.The advantage of the toroidal core technology is that it allows toroidal distribution transformers to be realized in the highest power range, which are extremely low-loss and only about 50% of the operating costs of conventional distribution transformers in casting resin technology. As a result, the toroidal distribution transformer refinances in a few years and, in addition, a significant amount of primary energy, for the conservation of resources and the environment, can be saved.

Die Aufgabe wird auch gelöst durch einen Transformator, insbesondere eine spiralförmige Unterspannungswicklung hohen Querschnitts und deren Herstellung, ein mehrstufiger geschlossener Ringkerntransformatorkern hoher Stabilität, aus magnetisch leitendem und gegenseitig isoliertem Material, zur Unterspannungswicklung hin elektrisch isoliert, sowie dessen Herstellungsverfahren, wobei bevorzugt ein Trägergestell mit mindestens 3 Vorratsrollenvorrichtungen mit jeweils einer Bremsvorrichtung, mit mindestens 2 verschiedenen Breiten von magnetisch leitendem Material, mindestens drei Klebesprühvorrichtungen, sowie mindestens drei Aufwickelvorrichtungen mit einem Antriebssystem, mindestens drei Führungsvorrichtungen, einer Führungsschiene, sowie einer Abschneidevorrichtung vorgesehen ist.The object is also achieved by a transformer, in particular a spiral undervoltage winding high cross-section and their manufacture, a multi-stage closed toroidal transformer high stability, from magnetically conductive and mutually insulated material, electrically insulated for undervoltage winding, and its manufacturing method, preferably a support frame with at least 3 Vorratsrollenvorrichtungen, each with a braking device, with at least 2 different widths of magnetically conductive material, at least three Klebersprühvorrichtungen, and at least three Aufwickelvorrichtungen with a drive system, at least three guide devices, a guide rail, and a cutting device is provided.

Bei einem bevorzugten Ausführungsbeispiel ist ein Transformator vorgesehen, wobei jede Vorratsrollenvorrichtung, sowie jede Aufwickelvorrichtung mit einer Antriebs -und Bremsvorrichtung ausgestattet ist.In a preferred embodiment, a transformer is provided, wherein each supply roll device, as well as each take-up device is equipped with a drive and brake device.

Bei einem bevorzugten Ausführungsbeispiel ist ein Transformator vorgesehen, wobei mindestens drei Distanzringe oder jeweils drei Distanzstücke pro Windung, in den Stufungen des Ringkerns fest angebracht sind.In a preferred embodiment, a transformer is provided, wherein at least three spacer rings or three spacers per turn, are firmly attached in the gradations of the toroidal core.

Bei einem bevorzugten Ausführungsbeispiel ist ein Transformator vorgesehen, wobei der Ringkern mit einem Lack zur Isolation und zum Schutz gegen Korrosion überzogen ist.In a preferred embodiment, a transformer is provided, the toroidal core being coated with a varnish for insulation and for protection against corrosion.

Bei einem bevorzugten Ausführungsbeispiel ist ein Transformator vorgesehen, wobei der Ringkerntransformatorkern mit einem hochfesten Gießharz eingehüllt ist.In a preferred embodiment, a transformer is provided wherein the toroidal transformer core is encased in a high strength cast resin.

Die Aufgabe wird auch gelöst durch einen Transformator, insbesondere eine spiralförmige Unterspannungswicklung hohen Querschnitts und deren Herstellung, ein mehrstufiger geschlossener Ringkerntransformatorkern hoher Stabilität, aus magnetisch leitendem und gegenseitig isoliertem Material, zur Unterspannungswicklung hin elektrisch isoliert, sowie dessen Herstellungsverfahren, wobei eine Windung der Unterspannungswicklung aus einem elektrisch leitendem Material in zwei Hälften vorgeformt wird, diese zwei Hälften um den geschlossenen Ringkern elektrisch leitend miteinander verbunden werden, wobei mindestens eine Hälfte eine Etage aufweist, damit eine spiralförmige Wicklung, bestehend aus mehreren Windungen auf dem geschlossenen Ringkern entsteht.The object is also achieved by a transformer, in particular a spiral low-voltage winding of high cross-section and their manufacture, a multi-stage closed toroidal transformer high stability, from magnetically conductive and mutually insulated material, electrically insulated for undervoltage winding, and its manufacturing process, wherein a turn of the low-voltage winding an electrically conductive material is preformed in two halves, these two halves are electrically conductively connected to each other around the closed ring core, wherein at least one half has a floor, so that a spiral winding, consisting of several turns on the closed ring core is formed.

Bei einem bevorzugten Ausführungsbeispiel ist ein Verfahren vorgesehen, wobei die Windungshälften miteinander verschraubt oder/und verschweißt werden.In a preferred embodiment, a method is provided, wherein the winding halves are screwed together or / and welded.

Nachstehend ist die Erfindung anhand von Figuren näher erläutert.

Fig. 1
zeigt in schematischer Darstellung einen seitlichen Schnitt durch einen Mehrphasentransformator mit drei in axialer Richtung benachbart angeordneten Ringkernen.
Figur 2
zeigt in schematischer Darstellung ein Ausführungs-beispiel eines Wicklungsträgers und des Wickelvorgangs gemäß der vorliegenden Erfindung.
The invention is explained in more detail with reference to figures.
Fig. 1
shows a schematic representation of a lateral section through a multi-phase transformer with three axially adjacent arranged ring cores.
FIG. 2
shows a schematic representation of an embodiment of a winding support and the winding process according to the present invention.

In Figur 1 ist ein im Ganzen mit 101 bezeichneter Mehrphasentransformator dargestellt, der drei in axialer Richtung übereinander angeordnete Ringkerne 102 aufweist. Jeweils benachbarte Ringkerne 102 tragen dabei Phasenwicklungen unterschiedlicher Phasen, wobei die Phasenwicklungen jeweils auf die Ringkerne 102 ringförmig umschließenden Spulenkörpern 103 aufgebracht sind. Dabei können abwechselnd Spulenkörper 103 jeweils mit Primär und Sekundärwicklungen nebeneinander oder übereinander angeordnet sein. Es ist auch möglich, dass auf einen Spulenkörper 103 jeweils primär- und Sekundärwicklungen gemeinsam aufgebracht sind.In FIG. 1 is a generally designated with 101 polyphase transformer having three stacked axially in the axial direction of ring cores 102. In each case adjacent ring cores 102 carry phase windings of different phases, wherein the phase windings are respectively applied to the ring cores 102 annularly enclosing bobbins 103. In this case, bobbin 103 may be alternately arranged with primary and secondary windings next to each other or one above the other. It is also possible for primary and secondary windings to be applied together to a bobbin 103.

Die Ringkerne 102 sind in einer Haltevorrichtung 104 angeordnet, die äußere sowie innere Führungsschienen 105a, 105b zur Bildung eines Aufnahmebereiches für die Ringkerne 102 aufweist. Die Führungsschienen 105a, 105b bestehen jeweils aus isolierendem Material, so dass die Ringkerne 102 beziehungsweise die Phasenwicklungen auf den Spulenkörper 103 der Ringkerne 102 seitlich nach außen hin isoliert sind.The ring cores 102 are arranged in a holding device 104 which has outer and inner guide rails 105a, 105b for forming a receiving region for the toroidal cores 102. The guide rails 105a, 105b are each made of insulating material, so that the ring cores 102 and the phase windings on the bobbin 103 of the ring cores 102 are laterally outwardly insulated.

Die Haltevorrichtung 104 weist unterseitig ein Bodenteil 107 auf, das ebenfalls aus isolierendem Material besteht. An dem Bodenteil 107 sind isolierende Auflageelemente 108 für den unteren Ringkern 102 vorgesehen. Dabei können mehrere voneinander beabstandete Auflageelemente 108 vorgesehen sein, oder es ist ein durchgehender Ring als Auflageelement 108 vorgesehen. Zwischen den einzelnen Ringkernen 102 sind jeweils Distanzstücke 109 vorgesehen, mit denen die Ringkerne 102 beziehungsweise die den Ringkernen 102 jeweils zugeordneten Spulenkörper 103 in ihrer Lage zueinander fixiert werden. Oberhalb des oberen Ringkernes 102 sind wiederum isolierende Auflageelemente 108 vorgesehen, auf denen ein Deckelteil 110 aufliegt und die Ringkerne 102 auch oberseitig nach außen hin isoliert.The holding device 104 has on its underside a bottom part 107, which likewise consists of insulating material. On the bottom part 107 insulating support elements 108 are provided for the lower ring core 102. In this case, a plurality of spaced bearing elements 108 may be provided, or it is a continuous ring as a support element 108 is provided. Spacers 109 are respectively provided between the individual ring cores 102 with which the ring cores 102 or the coil cores 103 respectively assigned to the toroidal cores 102 are fixed relative to one another in their position. Insulating support elements 108 are again provided above the upper ring core 102, on which a cover part 110 rests and the toroidal cores 102 are also insulated on the upper side towards the outside.

Der in der Figur 1 dargestellte Mehrphasentransformator 101 ist als Drei-Phasen-Transformator ausgebildet. Die nicht näher dargestellten Anschlussstellen der einzelnen Phasenwicklungen der Ringkerne 102 beziehungsweise der Spulenkörper 103 sind jeweils um 120° zueinander versetzt angeordnet. Die Phasenwicklungen sind dadurch mechanisch um einen Winkel zueinander versetzt angeordnet, der der elektrischen Phasenverschiebung beziehungsweise dem elektrischen Phasenwinkel zwischen den Spannungssignalen dieser Phasenwicklungen entspricht.The Indian FIG. 1 shown polyphase transformer 101 is formed as a three-phase transformer. The connection points of the individual phase windings of the toroidal cores 102 or of the spool bodies 103, which are not illustrated in more detail, are each offset by 120 ° relative to one another. The phase windings are thereby mechanically offset from one another by an angle which corresponds to the electrical phase shift or the electrical phase angle between the voltage signals of these phase windings.

Insbesondere im Bereich der Distanzstücke 109, das heißt dort, wo benachbarte Ringkerne den geringsten Abstand zueinander haben, ist dadurch an zwei gegenüberliegenden Bereichen zweier Ringkerne 102 beziehungsweise Spulenkörper 103 praktisch kein Potentialunterschied vorhanden. Spannungsüberschläge zwischen benachbarten Ringkernen 102 sind so auch bei dicht aneinander angeordneten Ringkernen 102 nicht möglich. Der Mehrphasentransformator 101 kann dadurch kompakt und mit reduziertem Platzbedarf aufgebaut werden. Zudem sind zwischen den einzelnen Ringkernen 102, im Bereich der Distanzstücke 109 keine oder nur geringe Isolationsmaßnahmen erforderlich, wodurch Kosten gespart werden und die Konstruktion vereinfacht ist.In particular, in the region of the spacers 109, that is, where adjacent ring cores have the smallest distance from each other, there is practically no potential difference at two opposite regions of two ring cores 102 or bobbin 103. Voltage flashovers between adjacent toroidal cores 102 are thus not possible even if the toroidal cores 102 are arranged close together. The multi-phase transformer 101 can thereby be constructed compact and with reduced space requirements. In addition, between the individual ring cores 102, in the region of the spacers 109, no or only little insulation measures are required, whereby costs are saved and the construction is simplified.

Die Ringkerne 102 sind mit ihren jeweiligen Spulenkörpern 103 modulartig ausgebildet. Bei einem Defekt in einem dieser Module kann der betroffene Ringkern gegen ein Ersatzmodul ausgetauscht werden beziehungsweise das defekte Modul wird elektrisch abgetrennt und ein Ersatzmodul wird provisorisch an den Mehrphasentransformator 101 angeschlossen. Somit ist es nicht erforderlich, einen kompletten Transformator als Reservegerät bereitzuhalten, sondern es genügt, einen Ringkern mit den die Phasenwicklungen tragenden Spulenkörpern als Reservemodul bereitzuhalten. Dadurch werden Kosten gespart und der Platzbedarf für ein Reservegerät ist reduziert.The ring cores 102 are formed with their respective bobbins 103 like a module. In the event of a defect in one of these modules, the affected toroidal core can be exchanged for a replacement module or the defective module is electrically disconnected and a replacement module is provisionally connected to the polyphase transformer 101. Thus, it is not necessary to keep ready a complete transformer as a backup device, but it is sufficient to keep ready a ring core with the coil windings supporting the phase windings as a reserve module. As a result, costs are saved and the space required for a reserve device is reduced.

In Figur 2 ist eine im Ganzen mit 201 bezeichnete Wickelvorrichtung zum Bewickeln von Wicklungsträgern 202 dargestellt. Die Wickelvorrichtung zum Bewickeln von Wicklungsträgern 202 mit auf drehbar gelagerten Wicklungsmaterial-Bevorratungsrollen 203a bevorratetem Wicklungsmaterial 204a, 204b, weist zwei Wickelstationen 205 auf, die um 90 Grad voneinander beabstandet, an einem andeutungsweise dargestellten Ringkern 6, angeordnet sind. Die Wickelstationen 205 weisen jeweils ein Trägergestell 207, mit einer Halte- und Drehlagerung 208, für jeweils einen Wicklungsträger 202 auf. Die Wicklungsträger 202 sind jeweils konzentrisch um den Ringkern 206 angeordnet, wobei zwischen dem Ringkern 206 und den Wicklungsträgern 202, jeweils ein Luftspalt20 9 frei bleibt. Der Ringkern 206 wird dazu mit einer nicht dargestellten Haltevorrichtung in der gezeigten Position gehalten.In FIG. 2 a winding device, generally designated 201, for winding winding carriers 202 is shown. The winding device for winding winding carriers 202 with winding material 204a, 204b stored on rotatably mounted winding material storage rollers 203a has two winding stations 205, which are arranged at 90 degrees from one another, on a ring core 6 indicated as an option. The winding stations 205 each have a support frame 207, with a holding and pivot bearing 208, for each one winding support 202. The winding supports 202 are each arranged concentrically around the ring core 206, wherein an air gap 20 9 remains free between the ring core 206 and the winding supports 202. The ring core 206 is held with a holding device, not shown, in the position shown.

Die Halte- und Drehlagerungen 208, weisen drei jeweils an einer Rollenhalterung 211, drehbar gelagerte Rollen 210 als Wälzkörper auf, die den Wicklungsträger 202 beaufschlagen. Zwei der Rollen 210 stützen den Wicklungsträger 202 dabei von unten und bilden so eine stabile Auflage und die dritte Rolle 210 beaufschlagt den Wicklungsträger 202, von oben, so dass der Wicklungsträger 202 praktisch von drei Rollen 210 eingeklemmt und ein versehentliches Lösen des Wicklungsträgers 202 von der Halte- und Drehlagerung 208, vermieden ist. Die Rollen 210 sind mit einer nicht dargestellten Antriebs- und Bremsvorrichtung verbunden, mit der die Rollen in Richtung der Pfeile gedreht werden. Zwischen den Rollen 210 und dem Wicklungsträger 202 ist eine reibschlüssige Antriebs- und Bremsvorrichtung vorgesehen, so dass beim Drehen der Rollen 210 im Uhrzeigersinn, der Wicklungsträger 202 entgegengesetzt mitgedreht wird. Durch die Drehbewegung des Wicklungsträgers 202 wird das Wicklungsmaterial 204a, 204b von den drehbar gelagerten Wicklungsmaterial-Bevorratungsrollen 203a, 203b ab- und auf den Wicklungsträger 202 aufgewickelt. Dabei können die Wicklungsträger 202 der einzelnen Wickelstationen 205, gleichzeitig bewickelt werden.The holding and pivot bearings 208, three each have on a roller holder 211, rotatably mounted rollers 210 as rolling elements, which act on the winding support 202. Two of the rollers 210 support the winding support 202 while from below and thus form a stable support and the third roller 210 acts on the winding support 202, from above, so that the winding support 202 is practically pinched by three rollers 210 and accidentally releasing the winding support 202 of the Holding and pivot bearing 208 is avoided. The rollers 210 are connected to a drive and brake device, not shown, with which the rollers are rotated in the direction of the arrows. Between the rollers 210 and the winding support 202, a frictional drive and braking device is provided, so that when rotating the rollers 210 in a clockwise direction, the winding support 202 is rotated in opposite directions. As a result of the rotational movement of the winding carrier 202, the winding material 204a, 204b is detached from the rotatably mounted winding material storage rollers 203a, 203b and wound onto the winding carrier 202. In this case, the winding carriers 202 of the individual winding stations 205 can be wound simultaneously.

Die Wicklungsträger 202 bestehen aus einem hochfesten Isolationsmaterial, sind jeweils spulenkörperartig mit den Wickelraum 213 und seitlich begrenzenden Flanschen 214 ausgebildet. Das Isolationsmaterial wird zur Spannungsfestigkeit, insbesondere gegenüber der Unterspannungswicklung benötigt. Die hohe Festigkeit wird für den Wickelvorgang, sowie das halten des relativ schweren Wicklungsmaterials benötigt. Die Außenränder dieser Seitenflansche 214 dienen dabei als Beaufschlagungsflächen für die Rollen 210. Das Wicklungsmaterial 204a, 204b kann dabei zwischen den Seitenflanschen 214 auf den Wicklungsträger 202 geführt werden, ohne die Zufuhr des Wicklungsmaterials 204a, 204b durch die Rollen 210 zu behindern. Zudem bilden die Seitenflansche 214 eine Isolation zu benachbarten Wickelträger, sowie seitliche Begrenzung für das Wicklungsmaterial 204a, 204b.The winding carriers 202 are made of a high-strength insulating material, each coil-like with the winding space 213 and laterally defining flanges 214 are formed. The insulation material is required for dielectric strength, in particular with respect to the low-voltage winding. The high strength is needed for the winding process, as well as the holding of the relatively heavy winding material. The outer edges of these side flanges 214 serve as loading surfaces for the rollers 210. The winding material 204a, 204b can be guided between the side flanges 214 on the winding support 202 without hindering the supply of the winding material 204a, 204b by the rollers 210. In addition, the side flanges 214 form an insulation to adjacent coil carriers, as well as lateral boundary for the coil material 204a, 204b.

Die Rollen 210 sind an ihrer Rollenhalterung 211 jeweils gefedert und gedämpft gelagert. Dadurch lassen sich die Rollen 210, einer Halte- und Drehlagerung 208 auseinander bewegen, um einen Wicklungsträger 202, in die Halte- und Drehlagerung einsetzen und wieder entnehmen zu können. Zudem ist es möglich, Wicklungsträger unterschiedlicher Größe zu bewickeln.The rollers 210 are spring-loaded and damped at their roller holder 211, respectively. This allows the rollers 210, a holding and pivot bearing 208 move apart to use a winding support 202, in the holding and pivot bearing and remove again. In addition, it is possible to wind winding carriers of different sizes.

An jeder Wickelstation 205, sind jeweils eine erste Wicklungsmaterial-Bevorratungsrolle 203a, mit Leitermaterial 4a, sowie eine zweite Wicklungsmaterial-Bevorratungsrolle 203b mit Isolationsmaterial 204b, zum gleichzeitigen, lagenweise übereinander wickeln des Leiter- und des Isolationsmaterials, auf einen Wicklungsträger 202 vorgesehen.At each winding station 205, a first winding material storage roll 203a, with conductor material 4a, and a second winding material storage roll 203b with insulating material 204b, for simultaneously, layer by layer wrap the conductor and the insulating material, on a winding support 202 are provided.

Die Erfindung bezieht sich auf eine Oberspannungswicklung eines Ringkerntransformators, sowie auf deren Herstellungsverfahren, für Verteilungstransformatoren, auf Basis der Ringkerntechnologie.The invention relates to a high-voltage winding of a toroidal transformer, as well as their method of manufacture, for distribution transformers, based on toroidal technology.

Die Wickelstation mit einer am Wicklungsträger, bestehend aus zwei spannungsfesten Halbschalen mit Seitenflansch aus Isoliermaterial hoher Festigkeit, welche zu einer spannungsfesten runden Einheit um den geschlossenen Ringkern zusammengefügt, zur Aufnahme der Segmente der Oberspannungswicklung des Transformators, bestehend aus mindestens einem elektrischen Leiter und mindestens einem Isolationsmaterial mit einer am Wicklungsträger angreifenden Halte- und Drehlagerung zum drehbaren Lagern des Wicklungsträgers vorgesehen ist, damit der elektrische Leiter und das Isolationsmaterial auf einen geschlossenen Ringkern aufgewickelt werden kann.The winding station with one on the winding carrier, consisting of two voltage-resistant half-shells with side flange High-strength insulating material, which is assembled to form a voltage-resistant round unit around the closed ring core, for receiving the segments of the high-voltage winding of the transformer, consisting of at least one electrical conductor and at least one insulating material with a holding and pivot bearing engaging on the winding support for rotatably supporting the winding support is, so that the electrical conductor and the insulating material can be wound onto a closed ring core.

Claims (15)

Vorrichtung zur Herstellung der Oberspannungswicklung eines Ringkerntransformators, dadurch gekennzeichnet, dass wenigstens eine Wickelstation (205) mit einer Halte- und Drehlagerung (208) zum drehbaren Lagern eines Wicklungsträgers (202) des Ringkerntransformators vorgesehen ist, welche Halte- und Drehlagerung (208) mehrere, umfangseitig an dem Wicklungsträger (202) angreifende Rollen (210) oder dergleichen Wälzkörper aufweist, von denen wenigstens eine mit einer Antriebs- und Bremsvorrichtung verbunden ist, um den Wicklungsträger (202) anzutreiben und abzubremsen, damit der elektrische Leiter mit dem Isolationsmaterial auf einen geschlossenen Ringkern (206) aufgewickelt werden kann, wobei als Wicklungsmaterial Flachbänder verwendbar sind.Device for producing the high voltage winding of a toroidal transformer, characterized in that at least one winding station (205) with a holding and pivot bearing (208) for rotatably supporting a winding support (202) of the toroidal transformer is provided, which holding and pivot bearing (208) several, Rolling elements (210) or the like on the winding support (202), at least one of which is connected to a drive and brake device, to drive and decelerate the winding support (202), so that the electrical conductor with the insulation material to a closed Ring core (206) can be wound, being used as a winding material flat belts. Vorrichtung nach Anspruch 1, dadurch gekennzeichnet, dass der Wicklungsträger (202) aus zwei spannungsfesten Halbschalen mit Seitenflansch (214) aus Isoliermaterial hoher Festigkeit besteht, welche zu einer spannungsfesten Einheit um den geschlossenen Ringkern (206) zusammengefügt sind.Apparatus according to claim 1, characterized in that the winding support (202) consists of two voltage-resistant shells with side flange (214) made of high-strength insulating material, which are joined together to form a voltage-resistant unit around the closed ring core (206). Vorrichtung nach einem der Ansprüche 1 oder 2, dadurch gekennzeichnet, dass sich der Wicklungsträger (202) einstückig um dem geschlossenen Ringkern (206) befindet.Device according to one of claims 1 or 2, characterized in that the winding support (202) is integrally located around the closed ring core (206). Vorrichtung nach einem der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass zum gleichzeitigen Bewickeln mehrerer Wicklungsträger (202) mehrere, in Umfangsrichtung nebeneinander angeordnete Wickelstationen (205) vorgesehen sind.Device according to one of claims 1 to 3, characterized in that for simultaneously winding a plurality of winding carriers (202) a plurality of circumferentially juxtaposed winding stations (205) are provided. Vorrichtung nach einem der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass der Wicklungsträger (202) oder die Wicklungsträger jeweils konzentrisch um den Ringkern (206) angeordnet ist/sind.Device according to one of claims 1 to 4, characterized in that the winding support (202) or the winding support in each case concentrically around the toroidal core (206) is arranged / are. Vorrichtung nach einem der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass die Halte- und Drehlagerungen (208) jeweils drei an einer Rollenlagerung (211) drehbar gelagerte Rollen (210) als Wälzkörper aufweisen, die den Wicklungsträger (202) beaufschlagen, insbesondere wobei zwei der Rollen (210) den Wicklungsträger von unten stützen und die dritte Rolle (210) den Wicklungsträger (202) von oben beaufschlagt, so dass der Wicklungsträger (202) von den drei Rollen (210) praktisch eingeklemmt und ein versehentliches Lösen des Wicklungsträgers (202) von der Halte- und Drehlagerung (208) vermieden ist.Device according to one of claims 1 to 5, characterized in that the holding and pivot bearings (208) each have three on a roller bearing (211) rotatably mounted rollers (210) as rolling elements which act on the winding support (202), in particular two the rollers (210) support the winding carrier from below and the third roller (210) acts on the winding carrier (202) from above, so that the winding carrier (202) is practically clamped by the three rollers (210) and accidental release of the winding carrier (202 ) is avoided by the holding and pivot bearing (208). Vorrichtung nach einem der Ansprüche 1 bis 6, dadurch gekennzeichnet, dass wenigstens eine Wicklungsmaterial-Bevorratungsrolle (203a) mit Leitermaterial (204a) und wenigstens eine zweite Wicklungsmaterial-Bevorratungsrolle (203b) mit Isolationsmaterial (204b) zum gleichzeitigen, lagenweise Aufwickeln von Leitermaterial und Isolationsmaterial auf den Wicklungsträger (202) vorgesehen sind.Device according to one of claims 1 to 6, characterized in that at least one winding material storage roll (203a) with conductor material (204a) and at least one second winding material storage roll (203b) with insulation material (204b) for the simultaneous, layer-wise winding of conductor material and insulation material are provided on the winding support (202). Vorrichtung nach einem der Ansprüche 1 bis 7, dadurch gekennzeichnet, dass drei, vier oder fünf Wicklungsmaterial-Bevorratungsrollen zum gleichzeitigen Bewickeln eines Wicklungsträgers (202) vorgesehen sind, und dass zwei, drei oder vier der Wicklungsmaterial-Bevorratungsrollen Leitermaterial und eine dritte, vierte oder fünfte Wicklungsmaterial-Bevorratungsrolle Isolationsmaterial zum Isolieren trägt.Device according to one of claims 1 to 7, characterized in that three, four or five winding material storage rollers for simultaneously winding a winding support (202) are provided, and that two, three or four of the winding material storage rollers conductor material and a third, fourth or fifth winding material storage roll carries insulation material for insulation. Vorrichtung nach einem der Ansprüche 1 bis 8, dadurch gekennzeichnet, dass Wälzkörper (212) zur Lagerung des Wicklungsträgers (202) vorgesehen sind, die zur Anpassung an im Durchmesser und/oder der Umrissform unterschiedliche Wicklungsträger (202) gefedert und/oder gedämpft gelagert sind.Device according to one of claims 1 to 8, characterized in that rolling elements (212) are provided for mounting of the winding support (202), for adaptation are in the diameter and / or the outline different winding support (202) sprung and / or damped. Vorrichtung nach einem der Ansprüche 1 bis 9, dadurch gekennzeichnet, dass jede Vorratsrollenvorrichtung sowie jede Aufwickelvorrichtung mit einer Antriebs- und Bremsvorrichtung ausgestattet ist.Device according to one of claims 1 to 9, characterized in that each supply roll device and each take-up device is equipped with a drive and brake device. Verfahren zur Herstellung eines Transformators, dadurch gekennzeichnet, zum Bewickeln eines Wicklungsträgers (202) dieser in eine Halte- und Drehlagerung (206) einer Vorrichtung (201) nach einem der Ansprüche 1 bis 10 eingesetzt wird, dass das Wicklungsmaterial (204a, 204b) dem Wicklungsträger (202) von der oder den zu der Haltund Drehlagerung (206) beabstandet angeordneten Wicklungsmaterial-Bevorratungsrolle(n) (203a, 203b) zugeführt wird, dass mit einer Antriebs- und Bremsvorrichtung zumindest ein Wälzkörper (210) angetrieben bzw. abgebremst wird, wodurch der Wicklungsträger (202), an dem dieser Wälzkörper (210) umfangsseitig angreift, in Rotation gerät, wobei als Wicklungsmaterial Flachbänder verwendbar sind.Method for producing a transformer, characterized in that it is used for winding a winding carrier (202) into a holding and pivoting mounting (206) of a device (201) according to one of claims 1 to 10, in that the winding material (204a, 204b) Winding support (202) is supplied from the winding material storage roll (s) (203a, 203b) arranged at a distance from the holding or pivot bearing (206) such that at least one rolling element (210) is driven or braked by a drive and braking device, whereby the winding support (202) on which this rolling body (210) engages circumferentially, in rotation, wherein as a winding material flat strips are used. Verfahren nach Anspruch 11, dadurch gekennzeichnet, dass der Wicklungsträger (202) nach oder während dem Aufbringen der Oberspannungswicklung mit festem, flüssigen oder gasförmigem Isolationsmaterial gefüllt wird.A method according to claim 11, characterized in that the winding support (202) is filled after or during the application of the high-voltage winding with solid, liquid or gaseous insulating material. Verfahren nach einem der Ansprüche 11 bis 12, dadurch gekennzeichnet, dass eine teilbare Gießform zur Fertigung des Wicklungsträgers (202) um den geschlossenen Ringkern (206) gelegt wird und/oder der Wicklungsträger (202) in einem Druckgelierverfahren gefertigt wird und/oder der Wicklungsträger (202) nach dem Entfernen der Gießform bewickelt wird.Method according to one of claims 11 to 12, characterized in that a divisible mold for producing the winding support (202) is placed around the closed ring core (206) and / or the winding support (202) is manufactured in a Druckgelierverfahren and / or the winding support (202) is wound after removing the mold. Verfahren nach einem der Ansprüche 11 bis 13, dadurch gekennzeichnet, dass der Wicklungsträger (202) mit einem Gießharz unter atmosphärischen Bedingungen, einer Gießharzfüllung unter Vakuum, einer Gießharzfüllung durch ein Druckgelierverfahren oder bei einer dichten Ausführung mit gasförmigen oder flüssigen Isolationsstoffen, insbesondere Stickstoff oder ein isolierendes Öl, während oder nach dem Wickelvorgang gefüllt wird.Method according to one of claims 11 to 13, characterized in that the winding support (202) with a casting resin under atmospheric conditions, a Gießharzfüllung under vacuum, a Gießharzfüllung by a Druckgelierverfahren or in a dense execution with gaseous or liquid insulating materials, in particular nitrogen or a insulating oil is filled during or after the winding process. Verfahren nach einem der Ansprüche 11 bis 14, dadurch gekennzeichnet, dass Leitermaterial (204a, 204b) und Isolationsmaterial (204a, 204b) gleichzeitig lagenweise auf den Wicklungsträger (202) aufgewickelt werden.Method according to one of claims 11 to 14, characterized in that conductor material (204a, 204b) and insulation material (204a, 204b) are simultaneously wound in layers on the winding support (202).
EP08010496A 2004-10-07 2005-10-06 Method for manufacturing a transformer Not-in-force EP1959460B1 (en)

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DE102004048793A DE102004048793B3 (en) 2004-10-07 2004-10-07 Multiphase transformer for handling high voltage potential differences has single-aperture cores fitted adjacent each other in an axial direction
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EP05799949A EP1797573B1 (en) 2004-10-07 2005-10-06 Toroidal core transformer

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